Abstract: A battery pack for a direct current (DC) voltage bus includes a battery disconnect unit (BDU) operable for controlling a connection state of the battery pack with respect to the DC voltage bus, first and second battery sections, and six transfer conductors, e.g., busbars or cables/wires. The first battery section has first and second battery modules with corresponding battery cells. The first and second battery modules are connected in series. The first and second battery sections are connected in parallel. The second battery section has third and fourth battery modules each with additional battery cells, with the third and fourth battery modules connected in series. The six transfer conductors collectively interconnect the battery modules, sections, and BDU. A total battery current is divided equally between the battery sections, with the transfer conductors being rated for half of the total battery current.

Abstract: A battery electric system for a motor vehicle or another electrified system includes a battery pack connected to a direct current voltage bus, and having positive and negative battery terminals, a main pyrotechnic fuse (“pyro fuse”), a high-voltage (HV) component connected to the bus via an HV channel, a current sensing element connected to the HV component on the HV channel, and a control system configured to selectively disconnect the battery pack from the bus by transmitting a voltage signal to the main pyro fuse when a measured current value from the current sensor is indicative of a short-circuit fault. A channel switch may be connected to or integral with the current sensing element, and configured to disconnect the HV component from the bus by opening in response to the measured current value.

Abstract: A battery system for a motor vehicle or other system includes a voltage bus with positive and negative bus rails, and first and second battery packs. The battery packs are arranged between and connected to rails. High-voltage switches are collectively configured to selectively interconnect the battery packs in a series or parallel battery arrangement. The switches include a pair of mutually-exclusive three-way/two-position contactors each having a series connection position and parallel connection position corresponding to the respective series and parallel battery arrangements. An electric powertrain includes an electrical load connected to the battery system, and a controller coupled to the switches. In response to a battery mode selection signal, the controller selectively transitions the contactors from the series connection position to the parallel connection position, or vice versa. A motor vehicle includes road wheels, a body, and the electric powertrain.

Abstract: A rechargeable energy storage system (RESS) includes a battery controller and battery modules, each respective module having battery cells, a cell sense board, and a semiconductor switch. The switch is connected in parallel with the cells within the respective module, and configured to conduct an electrical current during a thermal runaway propagation (TRP) event in which one or more cells is in an open-circuit state. This action bypasses the module and enables electrical components to be powered by the RESS during the TRP event. A battery electric system includes a direct current (“DC”) voltage bus, an electrical component connected thereto, the battery controller, and the RESS. A method for constructing the RESS includes connecting a respective semiconductor switch in parallel with the at least one battery cell of each respective one of the multiple battery modules, and electrically connecting the multiple battery modules together to construct the RESS.

Abstract: A rechargeable energy storage system (RESS) includes a battery controller and battery modules, each respective module having battery cells, a cell sense board, and a semiconductor switch. The switch is connected in parallel with the cells within the respective module, and configured to conduct an electrical current during a thermal runaway propagation (TRP) event in which one or more cells is in an open-circuit state. This action bypasses the module and enables electrical components to be powered by the RESS during the TRP event. A battery electric system includes a direct current (“DC”) voltage bus, an electrical component connected thereto, the battery controller, and the RESS. A method for constructing the RESS includes connecting a respective semiconductor switch in parallel with the at least one battery cell of each respective one of the multiple battery modules, and electrically connecting the multiple battery modules together to construct the RESS.

Abstract: A three-state contactor for an electrical system having a battery pack and voltage bus rail includes first and second pairs of electrical terminals. The first pair of terminals is separated by a first circuit gap in a first circuit path extending between the bus rail and an electrode terminal of the battery pack. The second pair of terminals is separated by a second circuit gap in a second circuit path extending between the bus rail and electrode terminal. A contactor arm, in response to a corresponding switch activation signal, translates in an orthogonal direction with respect to its longitudinal axis between a first ON state position, an OFF position, and a second ON position to close the first circuit gap, open both circuit gaps, or close the second circuit gap, respectively. A multi-pack battery system and an electric powertrain may use the contactor.

Abstract: A battery system includes high-voltage switches, including a multi-pole contactor. Multiple packs are connectable in a series or parallel configuration via the switches. The contactor includes first and second pairs of electrical terminals separated by a respective circuit gap, with respective contactor arms simultaneously closing or opening the gaps. At all times, internal switches formed by the gaps and arms have the same ON/OFF state corresponding to the circuit gaps both being closed or both being open. Two of the contactors may be used to connect the battery packs to a DC fast-charging station, and to connect electrode terminals of the battery packs to a bus rail, respectively. An electric powertrain includes the battery system and an electrical load, including a rotary electric machine, that is connected to a power inverter and to a mechanical load.

Abstract: Presented are integrated electrical interconnect board (ICB) assemblies for battery modules, rechargeable traction battery packs equipped with such ICB assemblies, and methods for making/using such ICB assemblies. A battery module for storing and supplying electrical energy includes multiple battery cells that are stacked in side-by-side facing relation with one another and each has a battery cell casing with an electrical terminal projecting therefrom. An electrically insulating module housing has a housing base that supports thereon the stacked battery cells. An integrated ICB assembly, which is attached to the module housing, includes a central cover in spaced facing relation to the housing base, endwalls projecting from the central cover, and multiple busbar connectors attached to the endwalls and electrically connected to the battery cells' electrical terminals.

Abstract: A battery system includes high-voltage switches, including a multi-pole contactor. Multiple packs are connectable in a series or parallel configuration via the switches. The contactor includes first and second pairs of electrical terminals separated by a respective circuit gap, with respective contactor arms simultaneously closing or opening the gaps. At all times, internal switches formed by the gaps and arms have the same ON/OFF state corresponding to the circuit gaps both being closed or both being open. Two of the contactors may be used to connect the battery packs to a DC fast-charging station, and to connect electrode terminals of the battery packs to a bus rail, respectively. An electric powertrain includes the battery system and an electrical load, including a rotary electric machine, that is connected to a power inverter and to a mechanical load.

Abstract: A battery system for a motor vehicle or other system includes a voltage bus with positive and negative bus rails, and first and second battery packs. The battery packs are arranged between and connected to rails. High-voltage switches are collectively configured to selectively interconnect the battery packs in a series or parallel battery arrangement. The switches include a pair of mutually-exclusive three-way/two-position contactors each having a series connection position and parallel connection position corresponding to the respective series and parallel battery arrangements. An electric powertrain includes an electrical load connected to the battery system, and a controller coupled to the switches. In response to a battery mode selection signal, the controller selectively transitions the contactors from the series connection position to the parallel connection position, or vice versa. A motor vehicle includes road wheels, a body, and the electric powertrain.

Abstract: A three-state contactor for an electrical system having a battery pack and voltage bus rail includes first and second pairs of electrical terminals. The first pair of terminals is separated by a first circuit gap in a first circuit path extending between the bus rail and an electrode terminal of the battery pack. The second pair of terminals is separated by a second circuit gap in a second circuit path extending between the bus rail and electrode terminal. A contactor arm, in response to a corresponding switch activation signal, translates in an orthogonal direction with respect to its longitudinal axis between a first ON state position, an OFF position, and a second ON position to close the first circuit gap, open both circuit gaps, or close the second circuit gap, respectively. A multi-pack battery system and an electric powertrain may use the contactor.

Abstract: A cooling system for a rechargeable energy system includes a plurality of bus bars, a cooling plate configured for cooling the plurality of bus bars and disposed in a thermally-conductive relationship with a portion of each of the plurality of bus bars, and an isolation component disposed between and in contact with the cooling plate and each of the plurality of bus bars. A rechargeable energy storage system and device are also described.

Abstract: Presented are integrated electrical interconnect board (ICB) assemblies for battery modules, rechargeable traction battery packs equipped with such ICB assemblies, and methods for making/using such ICB assemblies. A battery module for storing and supplying electrical energy includes multiple battery cells that are stacked in side-by-side facing relation with one another and each has a battery cell casing with an electrical terminal projecting therefrom. An electrically insulating module housing has a housing base that supports thereon the stacked battery cells. An integrated ICB assembly, which is attached to the module housing, includes a central cover in spaced facing relation to the housing base, endwalls projecting from the central cover, and multiple busbar connectors attached to the endwalls and electrically connected to the battery cells' electrical terminals.

Abstract: A cooling system for a rechargeable energy system includes a plurality of bus bars, a cooling plate configured for cooling the plurality of bus bars and disposed in a thermally-conductive relationship with a portion of each of the plurality of bus bars, and an isolation component disposed between and in contact with the cooling plate and each of the plurality of bus bars. A rechargeable energy storage system and device are also described.

Abstract: A battery pack for use with a supply of heat transfer fluid includes a plurality of battery modules arranged in one or more rows, and an elongated backplane positioned between the rows or adjacent to one row. The backplane has external longitudinal surfaces, and includes multiple bus bar assemblies equal in number to the number of battery modules and connected to the external longitudinal surfaces. The elongated backplane defines internal conduits configured to receive heat transfer fluid from the supply and extending along a length of the backplane adjacent to the bus bar assemblies. End plates of the battery modules include negative and positive voltage terminals mating with corresponding electrical connectors of a respective one of the bus bar assemblies. An electrical connection between each bus bar assembly and corresponding voltage terminals is established via a push-to-connect operation, with a finger-proof barrier covering the positive terminal.

Abstract: System and methods for retaining a battery system included in a vehicle are presented. In certain embodiments, a system for enclosing a battery system may utilize a plurality of modular components. The modular components may include a plurality of first side components and a plurality of second side components coupled to the plurality of first side components. A first top component and a second top component may be coupled to the first side components. In certain embodiments, the second top component may be configured to prevent the first top component from being decoupled from the first side components.

Abstract: A battery cell has a main body including active material configured to generate power from an electrochemical reaction. A first terminal is disposed on the main body and includes an integrated busbar. The integrated busbar is configured to place the battery cell in electrical communication with a second terminal of an adjacent battery cell.

Abstract: A battery module includes two or more battery cells and a continuous wave fin disposed between the battery cells. The construction of the wave fin is generally one-piece such that fewer parts are needed to form the battery module. In a preferred form, the wave fin is made from a high thermal conductivity material to promote removal of heat generated by the batteries during their operation. Portions of the wave fin not in direct contact with the battery cells may be placed in direct contact with a heat sink to help remove excess heat from the module. Expansion units or related additional structure may be placed, along with the various battery cells, between the generally serpentine-shaped wave fin to provide uniformity in cell spacing. A method of making one or more battery modules is also described.

Abstract: System and methods for retaining a battery system included in a vehicle are presented. In certain embodiments, a system for enclosing a battery system may utilize a plurality of modular components. The modular components may include a plurality of first side components and a plurality of second side components coupled to the plurality of first side components. A first top component and a second top component may be coupled to the first side components. In certain embodiments, the second top component may be configured to prevent the first top component from being decoupled from the first side components.

Abstract: A battery module includes two or more battery cells and a continuous wave fin disposed between the battery cells. The construction of the wave fin is generally one-piece such that fewer parts are needed to form the battery module. In a preferred form, the wave fin is made from a high thermal conductivity material to promote removal of heat generated by the batteries during their operation. Portions of the wave fin not in direct contact with the battery cells may be placed in direct contact with a heat sink to help remove excess heat from the module. Expansion units or related additional structure may be placed, along with the various battery cells, between the generally serpentine-shaped wave fin to provide uniformity in cell spacing. A method of making one or more battery modules is also described.